Ceramic welding method based on brazing

Abstract

The invention relates to the technical field of ceramic welding methods, in particular to a ceramic welding method based on brazing. The method comprises the following steps: step 1, cutting a prepared material; step 2, molding the prepared material; step 3, polishing the prepared material; step 4, soaking the prepared material; through the steps of prepared material molding, prepared material polishing, prepared material soaking and the like, impurities can be efficiently removed, the purity of the brazing filler metal and the ceramic material is improved, the welding quality is improved, the stable performance of welding is ensured, meanwhile, the proper scaling powder and the proper film-forming agent are selected, the brazing filler metal and the ceramic material can be coated, heating fusion can be better conducted, filling of a welding seam is completed, and the welding quality is improved. Gaps and air holes are prevented, and the overall welding effect is improved.

Description

Technical Field

[0001] The invention relates to the technical field of ceramic welding methods, and in particular to a ceramic welding method based on brazing. Background Art

[0002] Brazing is a type of welding that uses a filler metal with a lower melting point than the weldment as a filler metal, which is heated to a molten state and then filled into the weld to connect metals. The characteristics of brazing include: smooth joint surface, good air tightness, stable shape and size, and can connect the same or different metals and some non-metals.

[0003] Ceramic welding is a technology that uses welding technology to connect two ceramic parts into a whole. Ceramic materials have the characteristics of high strength, high temperature resistance, and high hardness. Ceramic brazing can achieve effective connection between ceramics and ceramics or ceramics and other materials. In the process of traditional brazing, due to the impurities attached to the weld itself and the rough surface of the brazing seam, with high temperature heating, the brazing material only fills the seam on one side and does not complete the fillet, so that the temperature conduction between the weld and the brazing material is not compatible, resulting in poor brazing seam formation, so that the weld cannot be effectively filled, gaps and pores occur, affecting the overall welding effect.

[0004] Therefore, in order to address the above-mentioned problem that due to the impurities attached to the weld itself and the rough surface of the brazing seam, the brazing material only fills the seam on one side during high-temperature heating and fails to complete the rounded corners, resulting in incompatible temperature conduction between the weld and the brazing material, leading to poor brazing seam formation, a ceramic welding method based on brazing can be designed. Summary of the invention

[0005] In order to overcome the problem that the weld itself has impurities attached and the surface of the brazing seam is rough, with high-temperature heating, the brazing material only fills the seam on one side and does not complete the fillet, making the temperature conduction between the weld and the brazing material incompatible, resulting in poor brazing seam formation and affecting the overall welding effect.

[0006] The technical solution of the present invention is: a ceramic welding method based on brazing, comprising the following steps; Step 1: Material preparation and cutting Select ceramic raw materials of corresponding size, use water jet cutting machine to cut the ceramic raw materials into 0.2mm-0.6mm thickness, and simultaneously cut the brazing materials into 300mm-500mm length; Step 2: Prepare materials and shape Select multiple groups of 300mm to 500mm long brazing materials, put them into an electric heating furnace for calcination and tempering, and use a static press to forge them into long strips; Step 3: Material preparation and polishing Polish the ceramic material, brazing material and welded parts in sequence to remove surface dirt and impurities, grind off 0.1mm to 0.3mm, and add hydrocarbon cleaning agent for ultrasonic cleaning; Step 4: Prepare and soak the ingredients Select an immersion box, add pure water, flux and film-forming agent according to the ratio of 1:1.5:0.3, put in a heating rod, stir and heat while mixing, put in ceramic material and solder in turn, soak for 5 to 10 minutes, fill the solution into a spray bottle, and atomize the weldment position; Step 5: Prepare ingredients Select a bench vise and a robotic arm, and use the bench vise to position the weldment. Extend a set of spray tubes on both sides and aim them around the welding area, and aim a set of air jet tubes at the welding area. Assemble the cleaned ceramic and brazing material together, and use a welding gun to perform welding operations.

[0007] Preferably, through the steps of material preparation shaping, material preparation polishing and material preparation soaking, impurities can be efficiently removed, the purity of the solder and ceramic materials can be increased, the quality of welding can be improved, and the stability of welding can be ensured. At the same time, suitable flux and film-forming agent can be selected to coat the solder and ceramic materials, which can better heat and blend them, complete the filling of the weld, prevent the formation of gaps and pores, and improve the overall welding effect.

[0008] Preferably, in step 2, the electric heating is first increased to 150-250°C for preheating for 5 minutes, then the solder is added and increased to 550-650°C for heating for 15 minutes, then the temperature is increased by 100°C every 5 minutes until 1200°C, maintained for 5-10 minutes, and then the temperature is stopped when it drops to 200°C, kept warm for 5-7 minutes, and then turned off and cooled to room temperature.

[0009] Preferably, in step 2, the drill rod is positioned using a positioning tool, and the static press pressure is controlled at 2MPa to 8MPa for a duration of 10 minutes.

[0010] Preferably, in step three, an automatic grinder is used to remove large impurities and attachments on the ceramic material, solder and weldment, and a hydrocarbon cleaning agent is mixed. The hydrocarbon cleaning agent is composed of water and non-aqueous solvents, acid-base cleaning agents, surfactants, oxidation-reduction agents and metal ion chelating agents, and the ratio is 15% to 20% of special type surfactants, 0.2% to 0.6% of antioxidants, 3% to 6% of demulsifiers and 73.4% to 81.8% of hydrocarbon solvents.

[0011] Preferably, in step three, pure water is pre-added to the ultrasonic cleaning machine, and the frequency is adjusted between 20kHz and 30kHz. After the cleaning agent is added, ceramic material and solder are added, the temperature is increased by 55 to 75°C, and the frequency is adjusted between 50kHz and 60kHz.

[0012] Preferably, in step four, the internal heater of the immersion box is preheated to a temperature of 15-25°C, and after adding pure water, flux and film-forming agent, the temperature is raised to 35-55°C, and ceramic material and solder are added in turn, the temperature is raised to between 55-75°C, and then stirred and mixed using an agitator.

[0013] Preferably, the soldering flux is composed of compound rosin, compound organic acid, compound halogen, thixotropic agent, compound antioxidant and compound brightener, with a ratio of 30-35% compound rosin, 10-15% compound organic acid, 0.2-0.4% compound halogen, 4-6% thixotropic agent, 1-2% compound antioxidant and 4-10% compound brightener; the film-forming agent is composed of modified rosin, phenolic resin, acrylic resin, modified epoxy resin and polyethylene glycol, with a ratio of 10-20% modified rosin, 20-35% phenolic resin, 5-10% acrylic resin, 30-35% modified epoxy resin and 40-55% polyethylene glycol.

[0014] Preferably, the welding area is atomized using a spray tube for 5 minutes so that the welding environment is kept clean and free of dust and smoke. The welding machine temperature is controlled between 1400°C and 1450°C for welding. After welding, the heat preservation cover is placed on the welded parts for 5 to 30 minutes. After another 10 minutes, the welded parts are cleaned using a set of jet tubes.

[0015] Beneficial effects of the present invention: In the traditional brazing process, impurities in the weldment, rough brazing seams and other problems lead to poor brazing seam formation, resulting in gaps and pores. Through the steps of material preparation shaping, material preparation polishing and material preparation soaking, impurities can be effectively removed, the purity of the brazing material and ceramic material can be increased, the quality of welding can be improved, and the stability of welding performance can be ensured. At the same time, the selection of suitable flux and film-forming agent can cover the brazing material and ceramic material, which can better heat and blend, complete the filling of the weld, prevent the formation of gaps and pores, and improve the overall welding effect. DETAILED DESCRIPTION

[0016] The following examples further illustrate the present invention.

[0017] The present invention provides an embodiment: a ceramic welding method based on brazing, comprising the following steps; Step 1: Material preparation and cutting Select ceramic raw materials of corresponding size, use water jet cutting machine to cut the ceramic raw materials into 0.2mm-0.6mm thickness, and simultaneously cut the brazing materials into 300mm-500mm length; Step 2: Prepare materials and shape Select multiple groups of 300mm to 500mm long brazing materials, put them into an electric heating furnace for calcination and tempering, and use a static press to forge them into long strips; Step 3: Material preparation and polishing Polish the ceramic material, brazing material and welded parts in sequence to remove surface dirt and impurities, grind off 0.1mm to 0.3mm, and add hydrocarbon cleaning agent for ultrasonic cleaning; Step 4: Prepare and soak the ingredients Select an immersion box, add pure water, flux and film-forming agent according to the ratio of 1:1.5:0.3, put in a heating rod, stir and heat while mixing, put in ceramic material and solder in turn, soak for 5 to 10 minutes, fill the solution into a spray bottle, and atomize the weldment position; Step 5: Prepare ingredients Select a bench vise and a robotic arm, and use the bench vise to position the weldment. Extend a set of spray tubes on both sides and aim them around the welding area, and aim a set of air jet tubes at the welding area. Assemble the cleaned ceramic and brazing material together, and use a welding gun to perform welding operations. Example 1

[0018] The present invention provides an embodiment: a ceramic welding method based on brazing, comprising the following steps; Step 1: Material preparation and cutting Select the corresponding size of ceramic wool, use the water jet cutting machine to cut the ceramic wool into 0.2mm thickness, and cut the brazing material into 300mm length at the same time; Step 2: Prepare materials and shape Select multiple groups of 300mm long brazing materials, put them into an electric heating furnace for calcination and tempering treatment, and use a static press to forge them into long strips. The electric heating is first raised to 150℃ for preheating for 5 minutes, then the brazing material is put in and raised to 550℃ for heating for 15 minutes, and then the temperature is raised by 100℃ every 5 minutes until it reaches 1200℃, and maintained for 5 minutes. When it drops to 200℃, stop cooling, keep warm for 5 minutes, turn off and cool to room temperature, and use a positioning tool to position the brazing rod. The static press pressure is controlled at 2MPa and the duration is 10 minutes. Step 3: Material preparation and polishing Polish the ceramic material, solder and weldment parts in turn to remove surface dirt and impurities, grind off 0.1mm, put in hydrocarbon cleaning agent for ultrasonic cleaning, use an automatic grinder to remove large impurities and attachments on the ceramic material, solder and weldment parts, and mix hydrocarbon cleaning agent. The hydrocarbon cleaning agent is composed of water and non-aqueous solvent, acid-base cleaning agent, surfactant, oxidizing-reducing agent and metal ion chelating agent. The ratio is 15% of special type surfactant, 0.2% of antioxidant, 3% of demulsifier and 73.4% of hydrocarbon solvent. Put in pure water in advance and adjust the frequency at 20kHz. After putting in the cleaning agent, put in the ceramic material and solder, increase the temperature by 55℃, and adjust the frequency at 50kHz. Step 4: Prepare and soak the ingredients Select an immersion box, add pure water, flux and film-forming agent according to the ratio of 1:1.5:0.3, put in a heating rod, stir and heat while mixing, put in ceramic material and solder in turn, soak for 5 minutes, fill the solution into the spray bottle, and atomize the weldment position. The internal heater of the immersion box is pre-heated at 15°C. After adding pure water, flux and film-forming agent, the temperature is raised to 35°C, and ceramic material and solder are put in in turn. After the temperature rises to 55°C, use a stirrer to stir and mix. The soldering flux is composed of compound rosin, compound organic acid, compound halogen, thixotropic agent, compound antioxidant and compound brightener, with a ratio of 30% compound rosin, 10% compound organic acid, 0.2% compound halogen, 4% thixotropic agent, 2% compound antioxidant and 4% compound brightener; the film-forming agent is composed of modified rosin, phenolic resin, acrylic resin, modified epoxy resin and polyethylene glycol, with a ratio of 10% modified rosin, 20% phenolic resin, 5% acrylic resin, 30% modified epoxy resin and 40% polyethylene glycol; Step 5: Prepare ingredients Select a bench vise and a robotic arm, and use the bench vise to position the weldment. Extend a group of spray tubes on both sides and aim them at the welding area, and aim a group of air jet tubes at the welding area. Assemble the cleaned ceramic and brazing material together, and use a welding gun to perform welding operations. Use a spray tube to atomize the welding area for 5 minutes so that the welding environment is kept clean and free of dust and smoke. Control the temperature of the welding machine at 1400℃ before welding. After welding, put the heat preservation cover on the welded part for 5 minutes. After another 10 minutes, use a group of air jet tubes to remove impurities from the welded part. Example 2

[0019] The present invention provides an embodiment: a ceramic welding method based on brazing, comprising the following steps; Step 1: Material preparation and cutting Select the corresponding size of ceramic wool, use the water jet cutting machine to cut the ceramic wool into 0.6mm thickness, and cut the brazing material into 500mm length at the same time; Step 2: Prepare materials and shape Select multiple groups of 500mm long brazing materials, put them into an electric heating furnace for calcination and tempering treatment, and use a static press to forge them into long strips. The electric heating is first increased to 250℃ for preheating for 5 minutes, then the brazing material is added and raised to 650℃ for heating for 15 minutes, and then the temperature is increased by 100℃ every 5 minutes until it reaches 1200℃, and maintained for 10 minutes. When it drops to 200℃, stop cooling, keep warm for 7 minutes, turn off and cool to room temperature, and use a positioning tool to position the brazing rod. The static press pressure is controlled at 8MP and lasts for 10 minutes. Step 3: Material preparation and polishing Polish the ceramic material, solder and weldment parts in turn to remove surface dirt and impurities, grind off 0.3mm, put in hydrocarbon cleaning agent for ultrasonic cleaning, use an automatic grinder to remove large impurities and attachments on the ceramic material, solder and weldment parts, and mix hydrocarbon cleaning agent. The hydrocarbon cleaning agent is composed of water and non-aqueous solvent, acid-base cleaning agent, surfactant, oxidizing-reducing agent and metal ion chelating agent. The ratio is 20% of special type surfactant, 0.6% of antioxidant, 6% of demulsifier and 81.8% of hydrocarbon solvent. Put in pure water in advance and adjust the frequency at 30kHz. After putting in the cleaning agent, put in the ceramic material and solder, increase the temperature by 75℃, and adjust the frequency at 60kHz. Step 4: Prepare and soak the ingredients Select an immersion box, add pure water, flux and film-forming agent according to the ratio of 1:1.5:0.3, put in a heating rod, stir and heat while mixing, put in ceramic material and solder in turn, soak for 10 minutes, fill the solution into the spray bottle, and atomize the weldment position. The internal heater of the immersion box is pre-heated at 25°C. After adding pure water, flux and film-forming agent, the temperature is raised to 55°C, and ceramic material and solder are put in in turn. After the temperature rises to 75°C, use a stirrer to stir and mix. The flux is composed of compound rosin, compound organic acid, compound halogen, thixotropic agent, compound antioxidant and compound brightener, with a ratio of 35% compound rosin, 5% compound organic acid, 0.4% compound halogen, 6% thixotropic agent, 2% compound antioxidant and 10% compound brightener. The film-forming agent is composed of modified rosin, phenolic resin, acrylic resin, modified epoxy resin and polyethylene glycol, with a ratio of 20% modified rosin, 35% phenolic resin, 10% acrylic resin, 35% modified epoxy resin and 55% polyethylene glycol. Step 5: Prepare ingredients Select a bench vise and a robotic arm, and use the bench vise to position the weldment. Extend a group of spray tubes on both sides and aim them at the welding area, and aim a group of air jet tubes at the welding area. Assemble the cleaned ceramic and brazing material together, and use a welding gun to perform welding operations. Use a spray tube to atomize the welding area for 5 minutes so that the welding environment is kept clean and free of dust and smoke. Control the temperature of the welding machine at 1450℃ before welding. After welding, put the heat preservation cover on the welded part for 30 minutes. After another 10 minutes, use a group of air jet tubes to remove impurities from the welded part.

Claims

1. A ceramic welding method based on brazing, characterized in that: The steps include: Step 1: Material preparation and cutting Select ceramic raw materials of corresponding size, use water jet cutting machine to cut the ceramic raw materials into 0.2mm-0.6mm thickness, and simultaneously cut the brazing materials into 300mm-500mm length; Step 2: Prepare materials and shape Select multiple groups of 300mm to 500mm long brazing materials, put them into an electric heating furnace for calcination and tempering, and use a static press to forge them into long strips; Step 3: Material preparation and polishing Polish the ceramic material, brazing material and welded parts in sequence to remove surface dirt and impurities, grind off 0.1mm to 0.3mm, and add hydrocarbon cleaning agent for ultrasonic cleaning; Step 4: Prepare and soak the ingredients Select an immersion box, add pure water, flux and film-forming agent according to the ratio of 1:1.5:0.3, put in a heating rod, stir and heat while mixing, put in ceramic material and solder in turn, soak for 5 to 10 minutes, fill the solution into a spray bottle, and atomize the weldment position; Step 5: Prepare ingredients Select a bench vise and a robotic arm, and use the bench vise to position the weldment. Extend a set of spray tubes on both sides and aim them around the welding area, and aim a set of air jet tubes at the welding area. Assemble the cleaned ceramic and brazing material together, and use a welding gun to perform welding operations.

2. A brazing-based ceramic welding method according to claim 1, characterized in that: In step 2, the electric heating is first increased to 150-250°C for preheating for 5 minutes, then the solder is added and increased to 550-650°C for heating for 15 minutes, then the temperature is increased by 100°C every 5 minutes until 1200°C, maintained for 5-10 minutes, and then stopped cooling when it drops to 200°C, kept warm for 5-7 minutes, and turned off and cooled to room temperature.

3. A brazing-based ceramic welding method according to claim 1, characterized in that: In step 2, the drill rod is positioned using a positioning tool, and the static press pressure is controlled at 2MPa to 8MPa for 10 minutes.

4. A brazing-based ceramic welding method according to claim 1, characterized in that: In step three, an automatic grinder is used to remove large impurities and attachments on the ceramic material, solder and weldment, and a hydrocarbon cleaning agent is mixed. The hydrocarbon cleaning agent is composed of water and non-aqueous solvents, acid-base cleaning agents, surfactants, oxidation-reduction agents and metal ion chelating agents. The ratio is 15% to 20% of special type surfactants, 0.2% to 0.6% of antioxidants, 3% to 6% of demulsifiers and 73.4% to 81.8% of hydrocarbon solvents.

5. A brazing-based ceramic welding method according to claim 1, characterized in that: In step 3, pure water is pre-added to the ultrasonic cleaning machine, and the frequency is adjusted between 20kHz and 30kHz. After adding the cleaning agent, ceramic material and solder are added, the temperature is increased by 55 to 75°C, and the frequency is adjusted between 50kHz and 60kHz.

6. A brazing-based ceramic welding method according to claim 1, characterized in that: In step 4, the internal heater of the immersion box is preheated to a temperature of 15-25°C. After adding pure water, flux and film-forming agent, the temperature is raised to 35-55°C. Ceramic material and solder are added in turn, the temperature is raised to 55-75°C, and then stirred and mixed using an agitator.

7. A brazing-based ceramic welding method according to claim 6, characterized in that: The soldering flux is composed of compound rosin, compound organic acid, compound halogen, thixotropic agent, compound antioxidant and compound brightener, and the proportion is 30-35% of compound rosin, 10-15% of compound organic acid, 0.2-0.4% of compound halogen, 4-6% of thixotropic agent, 1-2% of compound antioxidant and 4-10% of compound brightener. The film-forming agent is composed of modified rosin, phenolic resin, acrylic resin, modified epoxy resin and polyethylene glycol, and the proportion is 10-20% of modified rosin, 20-35% of phenolic resin, 5-10% of acrylic resin, 30-35% of modified epoxy resin and 40-55% of polyethylene glycol.

8. A brazing-based ceramic welding method according to claim 1, characterized in that: Use a spray tube to atomize the welding area for 5 minutes to keep the welding environment clean, free of dust and smoke. The welding machine temperature is controlled between 1400℃ and 1450℃ for welding. After welding, the insulation cover is placed on the welded parts for 5 to 30 minutes. After another 10 minutes, use a set of jet tubes to remove impurities from the welded parts.